U.S. patent application number 13/113762 was filed with the patent office on 2011-11-24 for charcoal barbecue grills.
Invention is credited to Jeffery F. Feng, Melvin Joshua Leedle, Bryce G. Rutter, Jon Scott Walters.
Application Number | 20110283990 13/113762 |
Document ID | / |
Family ID | 44971397 |
Filed Date | 2011-11-24 |
United States Patent
Application |
20110283990 |
Kind Code |
A1 |
Walters; Jon Scott ; et
al. |
November 24, 2011 |
CHARCOAL BARBECUE GRILLS
Abstract
A charcoal grill includes a vessel configured to hold and burn
charcoal for cooking food. The charcoal grill may include a
receptacle moveable between a first position in which the
receptacle is positioned for collecting ashes from charcoal burned
in the vessel and a second position in which the receptacle is
separated from the vessel for disposal of the collected ashes.
Additionally, or alternatively, the vessel may define a passage
extending from an exterior side of the vessel to an interior side
of the vessel for permitting a starter device to be inserted into
the passage for igniting charcoal within the vessel. Additionally,
or alternatively, the charcoal grill may include a vent system
including at least one vent opening extending through a portion of
the vessel, a vent cover movable with respect to the vent opening
between a closed position and an open position, and at least one
calibration associated with the vent cover between the closed
position and the open position.
Inventors: |
Walters; Jon Scott; (St.
Louis, MO) ; Rutter; Bryce G.; (St. Louis, MO)
; Leedle; Melvin Joshua; (St. Louis, MO) ; Feng;
Jeffery F.; (Chesterfield, MO) |
Family ID: |
44971397 |
Appl. No.: |
13/113762 |
Filed: |
May 23, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61347203 |
May 21, 2010 |
|
|
|
Current U.S.
Class: |
126/25R ;
126/25B; 126/9R |
Current CPC
Class: |
A47J 37/0759 20130101;
A47J 37/0704 20130101; A47J 2202/00 20130101; Y02A 40/928
20180101 |
Class at
Publication: |
126/25.R ;
126/9.R; 126/25.B |
International
Class: |
A47J 37/07 20060101
A47J037/07 |
Claims
1. A kamado-style charcoal grill, comprising: a vessel configured
to hold and burn charcoal for cooking food; and a receptacle
moveable between a first position in which the receptacle is
positioned for collecting ashes from charcoal burned in the vessel
and a second position in which the receptacle is separated from the
vessel for convenient removal and disposal of the collected ashes
by a user.
2. The kamado-style grill of claim 1 further comprising a
mechanical structure for retaining the receptacle in the first
position.
3. The kamado-style grill of claim 1 wherein the receptacle
includes a drawer configured for slideable movement between the
first position and the second position in a substantially
horizontal direction.
4. The kamado-style grill of claim 1 wherein the vessel includes an
opening extending between an interior of the vessel and an exterior
of the vessel, the receptacle configured for insertion through the
opening.
5. The kamado-style grill of claim 1 wherein the receptacle
includes an external grip portion configured for engagement by a
user when moving the receptacle between the first position and the
second position.
6. The kamado-style grill of claim 1 wherein the receptacle is part
of a removable unit including a vent structure for controlling
airflow through the kamado-style grill when the receptacle is in
the first position.
7. The kamado-style grill of claim 6 wherein the removable unit
includes a port through which a starter device can be inserted for
igniting charcoal in the vessel when the receptacle is in the first
position.
8. A charcoal grill comprising a vessel configured to hold and burn
charcoal for cooking food, the vessel defining a passage extending
from an exterior side of the vessel to an interior side of the
vessel, the passage permitting a starter device to be inserted into
the passage by a user from the exterior side of the vessel for
igniting charcoal within the vessel, and removed from the passage
from the exterior side of the vessel.
9. The charcoal grill of claim 8 further comprising a cover panel
moveable between a first position in which the cover panel covers
the passage and prevents insertion of the starter device into the
passage and a second position in which the cover panel permits
insertion of the starter device into the passage.
10. The charcoal grill of claim 9 wherein the cover panel is
coupled to the vessel for pivotal movement between the first
position and the second position.
11. The charcoal grill of claim 10 wherein the cover panel is
coupled to the vessel via a hinge extending along a top
substantially horizontal edge of the cover panel.
12. The charcoal grill of claim 8 further comprising a grate for
supporting charcoal, the grate positioned with respect to the
passage on the interior side of the vessel so the starter device is
positioned below the grate and below charcoal supported by the
grate when the starter device is inserted into the passage for
igniting the charcoal.
13. The charcoal grill of claim 12 wherein the grate is an upper
grate, the charcoal grill further comprising a lower grate
positioned below the upper grate, the upper grate and the lower
grate defining a pocket therebetween, the pocket substantially
aligned with the passage for permitting the starter device to be
inserted through the passage into the pocket from the exterior side
of the vessel for igniting the charcoal supported by the upper
grate.
14. The charcoal grill of claim 8 wherein the vessel includes a
removable unit, the removable unit defining a portion of the vessel
and the passage.
15. The charcoal grill of claim 14 wherein the removable unit
includes a vent structure for controlling airflow through the
charcoal grill when the receptacle is in the first position.
16. A charcoal grill comprising: a vessel configured to hold and
burn charcoal for cooking food; and a vent system comprising at
least one vent opening extending through a portion of the vessel, a
vent cover movable with respect to the vent opening between a
closed position and an open position, and at least one calibration
associated with the vent cover between the closed position and the
open position.
17. The charcoal grill of claim 16 wherein the vent system includes
a graduated series of calibrations.
18. The charcoal grill of claim 17 wherein the calibrations are
positioned on a non-moving portion of the charcoal grill.
19. The charcoal grill of claim 16 wherein the vent opening and the
vent cover are positioned on a lower portion of the charcoal grill
and configured to allow air to enter the vessel.
20. The charcoal grill of claim 19 wherein the vent cover comprises
a dial configured to be rotated by a user to selectively cover or
expose at least a portion of the vent opening.
21-25. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/347,203, filed on May 21, 2010, the entire
disclosure of which is incorporated herein by reference.
FIELD
[0002] The present disclosure generally relates to barbecue grills
for cooking and/or smoking food and, more particularly, to charcoal
barbecue grills.
BACKGROUND
[0003] This section provides background information related to the
present disclosure which is not necessarily prior art.
[0004] Many different types of barbecue grills are known for
cooking and/or smoking meats and other types of food. These grills
can generally be divided into two types: gas-fueled grills and
charcoal grills. Gas-fueled grills commonly use liquid propane or
natural gas as the primary fuel for cooking food over gas burners.
In contrast, charcoal grills are configured to hold and burn
charcoal to generate heat for cooking food. Of these two grill
types, charcoal grills are widely regarded by grilling enthusiasts
as imparting the best flavor to foods. Charcoal grills are commonly
available in a variety of configurations including, for example,
kettle-style charcoal grills, barrel-style charcoal grills,
kamado-style charcoal grills, etc.
SUMMARY
[0005] This section provides a general summary of the disclosure,
and is not a comprehensive disclosure of its full scope or all of
its features.
[0006] According to one aspect of the present disclosure, a
kamado-style charcoal grill includes a vessel configured to hold
and burn charcoal for cooking food, and a receptacle moveable
between a first position in which the receptacle is positioned for
collecting ashes from charcoal burned in the vessel and a second
position in which the receptacle is separated from the vessel for
convenient removal and disposal of the collected ashes by a
user.
[0007] According to another aspect of the present disclosure, a
charcoal grill includes a vessel configured to hold and burn
charcoal for cooking food. The vessel defines a passage extending
from an exterior side of the vessel to an interior side of the
vessel. The passage permits a starter device to be inserted into
the passage by a user from the exterior side of the vessel for
igniting charcoal within the vessel, and removed from the passage
from the exterior side of the vessel.
[0008] According to still another aspect of the present disclosure,
a charcoal grill includes a vessel configured to hold and burn
charcoal for cooking food, and a vent system including at least one
vent opening extending through a portion of the vessel, a vent
cover movable with respect to the vent opening between a closed
position and an open position, and at least one calibration
associated with the vent cover between the closed position and the
open position.
[0009] Further areas of applicability will become apparent from the
description provided herein. It should be understood that various
aspects of this disclosure may be implemented individually or in
combination with one or more other aspects, elements or features
described herein and/or illustrated in the drawings, and in a wide
variety of configurations. Accordingly, it should be understood
that the description and specific examples in this disclosure are
intended for purposes of illustration only and are not intended to
limit the scope of the present disclosure.
DRAWINGS
[0010] The drawings described herein are for illustrative purposes
only of selected embodiments and not all possible implementations,
and are not intended to limit the scope of the present
disclosure.
[0011] FIG. 1 is a perspective view of a charcoal grill according
to one example embodiment of the present disclosure with a cover of
the charcoal grill shown in a closed position;
[0012] FIG. 2 is a perspective view of the charcoal grill of FIG. 1
with the cover of the charcoal grill shown in an open position, and
with upper and lower cooking surfaces of a cooking rack shown
pivoted upward;
[0013] FIG. 3 is another perspective view of the charcoal grill of
FIG. 1;
[0014] FIG. 4 is an enlarged perspective view of a shock absorber
of the charcoal grill of FIG. 1, configured to help inhibit the
cover of the charcoal grill from slamming against a base of the
charcoal grill when moving to the closed position;
[0015] FIG. 5 is an exploded perspective view of the charcoal grill
of FIG. 1;
[0016] FIG. 6 is a perspective view of a fire bowl of the charcoal
grill of FIG. 1 shown above the base of the charcoal grill;
[0017] FIG. 7 is a top plan view of the charcoal grill of FIG. 1
with the cover removed to illustrate interior components of the
charcoal grill;
[0018] FIG. 8 is a perspective view of an ash drawer of the
charcoal grill of FIG. 1, configured for use to collect and remove
ashes from the charcoal grill;
[0019] FIG. 9 is a longitudinal section view of the charcoal grill
of FIG. 1;
[0020] FIG. 10 is a perspective view of a grate structure of the
charcoal grill of FIG. 1, configured to hold charcoal in the fire
bowl of the charcoal grill and allow the charcoal to be burned for
cooking operation;
[0021] FIG. 11 is a perspective view of part of an upper vent and
part of a lower vent of the charcoal grill of FIG. 1, each
illustrated in various different positions (a)-(j) for allowing
different amounts of airflow through the charcoal grill;
[0022] FIG. 12 is an exploded perspective view of part of the upper
vent shown in FIG. 11;
[0023] FIG. 13 is a perspective view of an ash drawer according to
another example embodiment of the present disclosure; and
[0024] FIG. 14 is a perspective view of an electric starter
suitable for use with the charcoal grill of FIG. 1 to ignite
charcoal in the charcoal grill.
[0025] Corresponding reference numerals indicate corresponding
parts throughout the several views of the drawings.
DETAILED DESCRIPTION
[0026] Example embodiments are provided herein so that this
disclosure will be thorough, and will fully convey the scope to
those who are skilled in the art. Numerous specific details are set
forth such as examples of specific components, devices, and
methods, to provide a thorough understanding of embodiments of the
present disclosure. It will be apparent to those skilled in the art
that specific details need not be employed, that example
embodiments may be embodied in many different forms and that
neither should be construed to limit the scope of the disclosure.
In some example embodiments, well-known processes, well-known
device structures, and well-known technologies are not described in
detail.
[0027] The terminology used herein is for the purpose of describing
particular example embodiments only and is not intended to be
limiting. As used herein, the singular forms "a," "an," and "the"
may be intended to include the plural forms as well, unless the
context clearly indicates otherwise. The terms "comprises,"
"comprising," "including," and "having," are inclusive and
therefore specify the presence of stated features, integers, steps,
operations, elements, and/or components, but do not preclude the
presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof. The
method steps, processes, and operations described herein are not to
be construed as necessarily requiring their performance in the
particular order discussed or illustrated, unless specifically
identified as an order of performance. It is also to be understood
that additional or alternative steps may be employed.
[0028] When an element or layer is referred to as being "on,"
"engaged to," "connected to," or "coupled to" another element or
layer, it may be directly on, engaged, connected or coupled to the
other element or layer, or intervening elements or layers may be
present. In contrast, when an element is referred to as being
"directly on," "directly engaged to," "directly connected to," or
"directly coupled to" another element or layer, there may be no
intervening elements or layers present. Other words used to
describe the relationship between elements should be interpreted in
a like fashion (e.g., "between" versus "directly between,"
"adjacent" versus "directly adjacent," etc.). As used herein, the
term "and/or" includes any and all combinations of one or more of
the associated listed items.
[0029] Although the terms first, second, third, etc. may be used
herein to describe various elements, components, regions, layers
and/or sections, these elements, components, regions, layers and/or
sections should not be limited by these terms. These terms may be
only used to distinguish one element, component, region, layer or
section from another region, layer or section. Terms such as
"first," "second," and other numerical terms when used herein do
not imply a sequence or order unless clearly indicated by the
context. Thus, a first element, component, region, layer or section
discussed below could be termed a second element, component,
region, layer or section without departing from the teachings of
the example embodiments.
[0030] Spatially relative terms, such as "inner," "outer,"
"beneath," "below," "lower," "above," "upper," and the like, may be
used herein for ease of description to describe one element or
feature's relationship to another element(s) or feature(s) as
illustrated in the figures. Spatially relative terms may be
intended to encompass different orientations of the device in use
or operation in addition to the orientation depicted in the
figures. For example, if the device in the figures is turned over,
elements described as "below" or "beneath" other elements or
features would then be oriented "above" the other elements or
features. Thus, the example term "below" can encompass both an
orientation of above and below. The device may be otherwise
oriented (rotated 90 degrees or at other orientations) and the
spatially relative descriptors used herein interpreted
accordingly.
[0031] As will be apparent, the teachings of this disclosure can be
implemented in a wide variety of charcoal grills of various types,
sizes and configurations (each referred to as an embodiment). For
example, the various teachings of this disclosure can be applied to
kettle-style charcoal grills and barrel-style charcoal grills that
are commonly formed of steel, as well as kamado-style charcoal
grills that are typically formed of clay, high fire ceramics,
refractory materials, traditional terra cotta, cement rock
compositions, etc.
[0032] Each charcoal grill typically includes a vessel of some type
configured to hold and burn charcoal to generate heat for cooking
food (e.g., by searing, grilling, baking, smoking, steaming, etc.).
While natural lump charcoal and charcoal briquettes are typically
preferred, wood may also be used as fuel in a charcoal grill.
Accordingly, as used herein, the term "charcoal" should be
understood to include wood.
[0033] A charcoal grill constructed according to this disclosure
may include a receptacle for collecting ashes. The receptacle may
be moveable between a first position in which the receptacle is
positioned for collecting ashes from charcoal burned in the vessel,
and a second position in which the receptacle is separated from the
vessel for convenient removal and disposal of the collected ashes
by a user. The receptacle may be configured for insertion into an
opening through the vessel. The receptacle may also form a portion
(such as a bottom portion) of the vessel when the receptacle is in
the first position. One or more mechanical structures may also be
provided for retaining the receptacle in the first position. These
mechanical structures may be integral with or separate from the
receptacle and/or vessel.
[0034] Additionally, or alternatively, a charcoal grill constructed
according to this disclosure may include a vessel that defines a
passage extending from an exterior side of the vessel to an
interior side of the vessel. The passage is configured (i.e., with
a size and/or shape) to permit a starter device to be inserted into
the passage by a user from the exterior side of the vessel for
igniting charcoal within the vessel. Suitable starter devices
include electric starters (typically having an electric coil or
loop), butane starters, matches, etc. The passage can be positioned
so that the starter device can be inserted below a grate supporting
charcoal in the vessel for igniting the charcoal from the bottom
side of the grate. Preferably, the starter device can be removed
from the passage after igniting the charcoal without also removing
burning charcoal. A cover panel may be provided to selectively
allow and inhibit access to the passage from the exterior side of
the grill. If the grill is provided with a receptacle for
collecting ashes and a passage for inserting a starter device,
these features can be implemented separately or integrated into a
single removable unit that includes the ash receptacle.
[0035] Further, a charcoal grill constructed according to the
present disclosure may also (or alternatively) include a vent
system that includes at least one vent opening extending through a
portion of the vessel, a vent cover movable with respect to the
vent opening between open and closed positions, and at least one
calibration associated with the vent cover between the closed
position and the open position. Each calibration may correspond to
a particular level of airflow through the charcoal grill and may
provide for graduated amounts of airflow (e.g., on a graduated
scale from no airflow to high airflow, etc.). If multiple vent
openings and vent covers are employed, each may be provided with
one or more independent calibrations. Alternatively, a continuous
series of calibrations may be associated with two or more vent
covers. The calibrations may be positioned on moving or non-moving
portions of the charcoal grill, including on the vent covers, on
non-moving portions of the vessel adjacent the vent covers, etc. A
vent opening, vent cover and associated calibration may be
positioned on a lower portion or an upper portion of the charcoal
grill, or both, for selectively allowing air to enter and/or exit
the vessel under user control. If the grill is also provided with a
receptacle for collecting ashes, the vent system can be implemented
separately or integrated into a single removable that includes the
ash receptacle.
[0036] It should be appreciated that individual elements or
features of particular example embodiments described herein are
generally not limited to those particular embodiments, but, where
applicable, are interchangeable and can be used in other selected
embodiments, even if not specifically shown or described. The same
may also be varied in many ways. Thus, charcoal grills may have any
desired combination of aspects, elements and/or features described
herein.
[0037] One example embodiment of a kamado-style charcoal grill
having an ash receptacle, a passage for a starter device and at
least one calibrated vent system will now be described with
reference to FIGS. 1-12. It should be understood, however, that the
teachings of this disclosure are not so limited, and can be applied
to a wide variety of other charcoal grills having, for example,
only an ash receptacle, only a passage for a starter device, or
only a calibrated vent system.
[0038] As shown in FIGS. 1-3, the illustrated charcoal grill 100
generally includes a vessel 102, a support structure 104 holding
the vessel 102, and shelves 106 coupled to side portions of the
vessel 102. The support structure 104 is configured to hold the
vessel 102 in a secure position and at a desired height for cooking
operation. And, the shelves 106 provide space, for example, for
supporting items when using the charcoal grill 100. The illustrated
support structure 104 includes multiple castors 108 such that the
support structure 104 can roll as desired for moving the charcoal
grill 100. In other example embodiments, support structures may
alternatively be stationary-type structures (e.g., structures
without wheels, etc.), etc. for supporting charcoal grills.
[0039] In the illustrated embodiment, the vessel 102 includes a
lower base 112 and an upper cover 114. The cover 114 is pivotally
coupled to the base 112 by a hinge structure 116. This allows the
cover 114 to pivot between a closed position in which the cover 114
is positioned over the base 112 and an open position in which the
cover 114 allows access into the base 112 (e.g., to access
charcoal, food, etc.). The hinge structure 116 includes a
spring-assist feature configured to help with opening and closing
movement of the cover 114. In the illustrated assembly, this
feature includes springs 120 tensioned toward the open position of
the cover 114 to assist with opening movement of the cover 114 by
urging the cover 114 to pivot to the open position. The springs 120
also help hold the cover 114 in the open position and resist
closing movement of the cover 114 (helping a user generally close
the cover 114, and inhibiting the cover 114 from inadvertently
slamming closed).
[0040] The vessel 102 also includes a shock absorber 122 mounted to
the base 112 of the vessel 102 to further help inhibit the cover
114 from slamming against the base 112 when moving to the closed
position. An enlarged view of the shock absorber 122 is shown in
FIG. 4. For example, as the cover 114 moves to the closed position,
the shock absorber 122 operates to initially engage the cover 114
and dampen the closing impact before the cover 114 actually engages
the base 112. This feature can substantially help protect the cover
114 and base 112 from damage, for example, if the cover 114
suddenly falls to the closed position, etc. In the illustrated
embodiment, the shock absorber 122 includes a spring-based
structure mounted to a forward portion of the base 112. In other
example embodiments, shock absorbers may include other structures
such as, for example, fluid-based structures, magnetic-based
structures, etc. located as desired on the vessel 102.
[0041] In the illustrated embodiment, a temperature control unit
124 (e.g., a thermometer, etc.) is positioned within the cover 114
of the vessel 102. The temperature control unit 124 operates to
measure and/or monitor temperature within the charcoal grill 100 as
needed.
[0042] With reference now to FIGS. 5-7, the illustrated charcoal
grill 100 also includes a fire bowl 128 configured to be disposed
within the vessel 102 and configured to hold charcoal in the vessel
102 (and allow the charcoal to burn) for use in cooking food. The
fire bowl 128 is removably positioned within the vessel 102 such
that it can be removed from the vessel 102 and then subsequently
positioned back in the vessel 102 as desired. This can allow the
fire bowl 128 to be easily cleaned, if need, separate from the
vessel 102. A grate structure 130 is positionable within the fire
bowl 128 for supporting the charcoal in the fire bowl 128 during
use of the charcoal grill 100 (only part of the grate structure 130
is shown in the fire bowl 128 in FIG. 7). The fire bowl 128 may be
formed from suitable materials such as, for example, high fire
ceramics, refractory materials, traditional terra cotta, cement
rock compositions, etc.
[0043] With additional reference to FIG. 8, an ash drawer 132 (also
termed a receptacle, a removable unit, etc.) is included for use to
collect and/or clean ashes from the charcoal grill 100, for
example, following cooking operation. In the illustrated
embodiment, the ash drawer 132 is configured to slide in a
substantially horizontal direction into and out of an opening 134
(FIGS. 5 and 6) in the base 112 of the vessel 102. For example, the
ash drawer 132 can initially be positioned in the opening 134 to
collect ashes from the burned charcoal (as illustrated in FIGS. 1
and 2). Here, a collection portion 132a of the ash drawer 132 is
located under the fire bowl 128 to collect the ashes, with the fire
bowl 128 acting to funnel the ashes through a lower opening 136
into the ash drawer 132. The ash drawer 132 can then be removed
(e.g., separated, etc.) from the base 112 by sliding the ash drawer
132 out of the opening 134 (via an external grip 138) for disposing
(e.g., dumping, etc.) the collected ashes. The ash drawer 132 of
the illustrated charcoal grill 100 eliminates need to rake the
ashes out of the base 112 (as often required by previous grill
designs). A detent can be provided on the ash drawer 132 to help
secure the ash drawer 132 in the opening of the base 112 when
positioned for collecting ashes. For example, the detent can
include a protrusion, bubble, dent, etc. on the ash drawer 132
configured to fit into a corresponding recess defined in the base
112, or any other acceptable retention mechanisms.
[0044] With additional reference now to FIG. 9, the illustrated
charcoal grill 100 further includes a passage extending from
outside the charcoal grill 100 into an interior portion thereof to
permit a starter device (e.g., an electric starter, a butane
starter, a match, etc.) to be inserted through the passage for
igniting the charcoal in the charcoal grill 100 (in particular, the
charcoal within the fire bowl 128). The passage includes a port 144
(see also FIG. 5) defined in the ash drawer and aligned openings
146, 148 (see also FIG. 6) defined in the base 112 and the fire
bowl 128. As such, the passage extends from outside the base 112 of
the charcoal grill 100, through the port 144 of the ash drawer 132
(when the ash drawer 132 is positioned in the opening 134 of the
base 112), and through the openings 146, 148 of the base 112 and
fire bowl 128.
[0045] A cover panel 150 (see also FIG. 8) is coupled to the ash
drawer 132 to selectively allow and inhibit access to the passage
from outside the charcoal grill 100. In the illustrated embodiment,
the cover panel 150 is pivotally coupled to the ash drawer 132 by a
spring-type hinge 152 (FIG. 8) extending along a top, substantially
horizontal edge of the cover panel 150. The hinge 152 allows the
cover panel 150 to pivot relative to the ash drawer 132 between a
closed position blocking the passage of the charcoal grill 100 (at
the port 144 of the ash drawer 132) and an open position allowing
access into the passage. As such, the cover panel 150 can be
pivoted open when the starter device is inserted through into the
passage (via the port 144) for use in igniting the charcoal, and
then pivots closed (via the spring action of the hinge) when the
starter device is removed. When closed, the cover panel 150 not
only blocks access into the passage but also inhibits flaming
embers from exiting the grill through the port 144. Alternatively,
the cover panel 150 could be coupled to the ash drawer 132
differently than illustrated herein, for example, slidably coupled,
removably coupled, etc.
[0046] As previously described, the grate structure 130 is
configured to be positioned within the fire bowl 128 to support the
charcoal therein (and allow the charcoal to be burned as desired).
With reference to FIGS. 9 and 10, the grate structure 130 includes
a base grate 154 (also referred to as a lower grate) and a
perforated cage 156 (also referred to as an upper grate) coupled
thereto (e.g., via a mechanical fastener, etc.). This construction
provides a two tier charcoal support that defines a pocket 158
above the base grate 154 and below the perforated cage 156, and
generally under the charcoal when supported on the grate structure
130. When the grate structure 130 is positioned in the fire bowl
128 (FIG. 9), the pocket 158 is oriented in general alignment with
passage of the charcoal grill 100 so that the starter device can be
inserted through the passage and into the pocket 158 for igniting
the charcoal on the grate structure 130. As such, the pocket 158
operates to separate the starter device from the charcoal so that
the starter device can be removed from the charcoal grill 100 after
igniting the charcoal without also removing burning charcoal
therewith. In the illustrated embodiment, the perforated cage 156
has a generally rectangular cross-section such that the pocket 158
also includes a rectangular cross-section. However, the perforated
cage 156 (and thus the pocket 158) could include other shapes as
desired.
[0047] With reference now to FIGS. 1, 5, 11, and 12, the
illustrated charcoal grill 100 includes a vent system for
controlling airflow through the charcoal grill 100 (and thus
temperature within the charcoal grill 100). The vent system
includes an upper vent 164 disposed in the cover 114 of the vessel
102 and a lower vent 166 (also referred to as a temperature control
panel or a temperature control zone) disposed, collectively, in the
base 112 and the ash drawer 132. This allows airflow in the
charcoal grill 100 generally between the lower vent 166 and the
upper vent 164. Components of the upper and lower vents 164, 166
may be constructed from stainless steel, cast iron, thermally
insulating materials, and/or may be powder coated as desired.
[0048] The upper and lower vents 164, 166 are each operable between
a closed position (FIG. 1 and FIG. 11(e)) where airflow through the
vent is inhibited and various open positions (FIG. 11) where
airflow is allowed. The upper vent 164 includes a vent opening 168
(FIG. 5) in the cover 114, a base portion 170 positioned over the
vent opening 168, and a vent cover 172 positioned over the base
portion 170 (FIG. 12). The base portion 170 includes multiple slots
174a aligned with the vent opening 168 in the cover 114. And, the
vent cover 172 is configured to rotate (via use of a thermally
insulated handle 172a) over the base portion 170 to selectively
cover the slots 174a and expose the slots 174a (by aligning slots
174b of the vent cover 172 with the slots 174a of the base portion
170), thus operating the upper vent 164 between the closed and open
positions. The lower vent 166 also includes a vent opening in the
vessel base 112 (which corresponds to base opening 134 and which
may also be referred to as a vent opening herein) and a vent cover
180 associated with the ash drawer 132. The vent cover 180 is
positioned in alignment with the opening 134 when the ash drawer
132 is located in the vessel 102 to collect ashes. In the
illustrated embodiment, the vent cover 180 includes two
semicircular dials 182a, 182b coupled to the ash drawer 132 and
configured to rotate to selectively cover and expose the opening
134 through the ash drawer 132 (and thus operate the lower vent 166
between the closed and open position). A screen 184 is provided on
the ash drawer 132 between the opening 134 and the dials 182a, 182b
to inhibit embers from the burning charcoal from exiting the vessel
102 through the opening 134. In the illustrated embodiment, the
dials 182a, 182b are about the same size. In other example
embodiments, however, dials having different sizes may be provided
to allow for different scales of adjustment of airflow through vent
openings.
[0049] For example, dial 182a could be smaller than dial 182b. In
that event, the smaller dial 182a could be used primarily for
smoking food (e.g., with the larger dial 182b is in its closed
position), and the larger dial 182b could be used for grilling
and/or searing foods (e.g., while the smaller dial 182a is in its
closed or open position, depending on the size of the dials 182a,
182b and the overall grill configuration). Further, each dial 182a,
182b could have one or more associated calibrations (e.g., either
two sets of calibrations or a continuous series of calibrations for
both dials), as further described below.
[0050] The upper and lower vents 164, 166 each include calibrations
188 provided between the closed position and the open position. The
calibrations 188 correspond to different airflow through the vents
164, 166 (e.g., different volumes of airflow through the vents 164,
166, etc.). And, the calibrations 188 are provided on a graduated
scale ranging from no airflow through the charcoal grill 100 up to
high airflow through the charcoal grill 100 (with graduated amounts
of airflow provided in between). As such, the calibrations 188
effectively define how much of each vent opening 168, 134 is
exposed by the corresponding vent cover 172, 180. Example
positioning of the vent covers 172, 180 of the upper and lower
vents 164, 166 relative to the various calibrations 188 are
illustrated in FIG. 11 in (a)-(j).
[0051] The upper and lower vents 164, 166 can be operated
individually to control airflow through the charcoal grill 100, or
they can be operated in sync together (as illustrated in FIG. 11).
Such control allows users to achieve specific temperatures for
specific cooking operations. The calibrations 188 allow users to
finitely adjust the airflow and temperature in the charcoal grill
100, and thus provide precise temperature control for different
cooking operations (e.g., smoking, searing, etc.). Moreover, the
calibrations 188 on the upper vent 164 and the calibrations on the
lower vent 166 can be coded for specific cooking operations (based
on the airflow through the charcoal grill 100 associated with the
calibrations 188). In the illustrated embodiment, the calibrations
188 include numeric indicators located on non-moving parts of the
vents 164, 166. In other example embodiments, calibrations may
include other indicators (e.g., alphabetic indicators, pectoral
indicators, etc.) and/or may be located on moving parts of the
vents 164, 166.
[0052] As shown in FIGS. 2 and 5, a cooking rack 192 is also
provided in the illustrated embodiment for use with the charcoal
grill 100. The cooking rack 192 includes upper and lower cooking
surfaces 194, 196 that together total almost 600 square inches. The
upper cooking surface 194 is removably coupled to the lower cooking
surface 196 such that the two surfaces 194, 196 can be separated
(and separately used) as desired. The upper cooking surface 194
includes a pivotable access portion 194a that allows access to the
lower cooking surface 196 (when the two cooking surfaces 194, 196
are coupled together). And similarly, the lower cooking surface 196
includes a pivotable access portion 196a that allows access to the
charcoal in the fire bowl 128 when the cooking rack 192 is
positioned in the vessel 102 (and when food is positioned on either
the upper or lower cooking surfaces 194, 196).
[0053] FIG. 13 illustrates another example embodiment of an ash
drawer 232 suitable for use with example embodiments of charcoal
grills as disclosed herein. The ash drawer 232 is configured for
use to collect and/or clean ashes from charcoal grills, for
example, following cooking operation. In this example embodiment,
the ash drawer 232 includes a slidable vent cover 280 for use with
a lower vent of a charcoal grill. The vent cover 280 is operable
between a closed position where airflow is inhibited and various
open positions where airflow is allowed. Calibrations 288 are
provided between the closed position and the open positions. The
calibrations 288 correspond to different airflow through the vent
portion of the ash drawer 232. In addition, a screen 284 is
provided to inhibit embers from burning charcoal from exiting the
charcoal grill through ash drawer when the vent cover 280 is open
(and the ash drawer 232 is positioned in a charcoal grill).
[0054] FIG. 14 illustrates an example electric starter 398 suitable
for use with example embodiments of charcoal grills disclosed
herein. As can be seen, the illustrated electric starter includes a
heater coil/loop 398a configured for use to ignite charcoal in
example embodiments of the charcoal grills (e.g., by way of
extending through a passage of a charcoal grill, etc.).
[0055] In example embodiments of the present disclosure, suitable
materials may be used in construction of different elements of
charcoal grills. For example, ash drawers may be constructed from
stainless steel, ceramic materials, combinations thereof, etc.
Cover panels may be constructed from ceramic materials. Grate
structures, support structures, other components, etc. may be
constructed from stainless steel. Vent portions may be constructed
from stainless steel, cast iron, etc. and/or may be powder
coated.
[0056] Specific dimensions and numeric values included herein are
exemplary in nature and do not limit the scope of the present
disclosure.
[0057] The foregoing description of the embodiments has been
provided for purposes of illustration and description. It is not
intended to be exhaustive or to limit the disclosure. Individual
elements or features of a particular embodiment are generally not
limited to that particular embodiment, but, where applicable, are
interchangeable and can be used in a selected embodiment, even if
not specifically shown or described. The same may also be varied in
many ways. Such variations are not to be regarded as a departure
from the disclosure, and all such modifications are intended to be
included within the scope of the disclosure.
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